Article of manufacture and method of making the same



March 27, 1945.

B. F. CONNER ARTCLE OF MANUFACTURE AND METHOD OF VMAKING THE SAME -Filed Jan. 5, 1942 5 Sheets-Sheet 1 B. F. CONNER ARTICLE- OF MANUFACTURE AND METHOD OF MAKING THE SAME n FiledV Jan. 5, 1942 sheets-Shen 2 -zyent .Esq/'amm E' Farmer ARTICLE OF MANUFACTURE AND METHOD OF MAKING TH SAME Filed Jan. 5, 1942` 5 sheets-sheet 3 March 27, l94. B.F. coNNER l 2,372,177

l AETLCLE oF MANUFACTURE AND METHOD GE MAKING THE SAME y I Filed Jan. "5, '1942 5 Sheets-Sheet 4 Eonner Eenjammj/ March 27, 1945 we, F.-c oNNER 2,372,177

ARTIGLE'OF MANUFACTURE AND METHOD OF MAKING THE SAME Filed Jan. 5, 1942 5 Sheets-Sheet 5- Patented 4Mar'.- 27.17945 ARTICLE Benjamin F. Conner,

or MANUrAc'rUas AND MErnop or mimic. 'rim` sans West Hartford, Conn., as-

signor to Colts Patent Fire Arms Manufacturing Company, of vConnecticut Y Hartford. Conn., a corporation spmieeue-nv Jennery s, 194s, serien No. 425374' (ci. is-ssi The invention relates to the4 manufacture of articles formed of materials exhibiting grain characteristics, Vthat is, materials which in their finished state show weakness along lines extending in one direction and have a relatively much greater strength along lines extending trans` versely to .the said lines of weakness. As used hereinafter the phrase effective grain direction" means the direction of the lines of weakness of materials exhibiting grain` characteristics.

TheY primary object avide articles made from a material exhibiting` 'grain characteristics 'that are of integral construction and have the effective grain direction of the material at and adjacent a surface thereof disposed angularly with respect tokthe effective grain direction of the material spaced from said surface. r

Another object is bultgr and sheet-like articles of the above charac r.

A further object is to provide a method of l ing articles of thelabove character.

Still further and other of the invention will be apparent from the vfol-4 lowing specification to .those skilled in the art.

of the invention is to proe objects and advantages v tion thereof indicated by the direction of the dash lines. In Fig. 1 it is shown that the matethetic resins such as.

Fig. 10 is asectional view IIl of Fig. 9.

Fig. 11 is a sectional view taken onthe line IIIIofFlg.9. l t

Fig. 12 is a fragmentary topi plan view of a portion of the molding machine and mold shown in '1. t

above pointed out. the invention relates to taken on the line vthe manufacture of articles from materials exhibiting grain characteristics. Among such materials and those to which the invention more particularly relates, but without limitation thereto, are cellulose acetate and the so-called synfor example, phenol-formaldehyde, methyl methacrylate. The said materials to which the invention more particularly relates are hereinafter designated as "resinous materials.\?r'v Referring to Figs. 1, 2 and 3. there is shown an integral cup-shaped article I having a circular bottom 2 and a cylindrical sidewall 3, the walls of the article being of relatively thin section and' the sidewall I being a surface of revolution. `The article I is formed o'f a material exhibiting grain l In the accompanying drawings I have shown several embodiments of the invention. but it will be understood that theldrawings are intended foiillustrative purposes oriily and are not to be construed as dening or the invention, the claims forming a part of this specification being relied upon for thatl'purpose.

In the drawings:

Fig. 1 is an elevational view of' an article incorporating the invention, a portion being broken away to illustrate certainfeatures thereof.

Figs. 2 and 3 are.` respectively, top and bottom plan viewsof the article shown in Fig. 1.

Fig. 4 is a perspective view of the article of Fig. 1 illustrating different articles' made therefrom.

Fig. 5 is 'an elevational view, of la pencil barrel incorporating the invention.

, Fis. .6 is-a sectional lview taken on the line C-l Fig. 7 is a lside elevationalview of a molding machine for carrying out the process of the invention.

Iy Fig. 8 is an enlarged sectional view taken on the line 8 8 of Fig. 11 but showing the mold in fully opened position. f

Fig. 9 is a side view-partly in section of the mold shown in Fig. 8, the mold being-shown in closed positionf I lllutlyilllsection,y

imiting the scope of characteristics and has the effective grain direcrial at and adjacent the inner surface of the cylndrical portion 3 has an effective grain direction extending helically thereof and that the outer or opposed surface has an effective grain direction extending longitudinally thereof. In Figs. `2 and 3 it is lshown that the effective grain of the inner bottom surface of the article I extends spirally while the effective grain direction of the outer bottom surface extends ra- It will be apparent that an article made as described so as to have the effective grain `direction of the material at and adjacent one sur.-v

' v. as indicated in Urespecttoi t ferent integral portions This face thereof extending angularly'with respect to the effective 'grain direction of the' material spaced from said surface will not be considerably weaker in one direction than in another as difthereof have their lines running in different directions. construction gives rise to what is in effect a laminated construction, although, of course, the article is of intesral construction rather than composed of a plurality of separate laminations.

' Referringnow to Fig. 4, there is shown a' sheet- 2* and of weakness this ngure, the effective grain the material at and adjacent one( each .article extends angularly with direction of surface of urea-formaldehyde, polystyrene and 7 a cylindrical tubular article the-material spaced from that surface.

The article shown in this figure may be made by cutting the bottom 2 from the cup-shaped article I shown in Figs. 1, 2 and 3. Figs. 5 and 6 show a conventionally shaped tubular article Il such as is used as a barrel for mechanical pencils. 'Ihe pencil barrel comprises a portion 5 of uniform section and a tapered end ii. It will be noted that the inner surface of the barrel is a surface of revolution while the outer surface may be of yany desired shape, a hexagonal cross section being shown. The pencil barrel is formed from a material exhibiting grain characteristics and has the effective grain direction of the material at and adjacent the inner surface extending helically of the barrel while the effective grain direction of the material at and adjacent the outer or opposed surface extends longitudinally of the barrel.

In accordance with the invention, articles incorporating the principles thereof, for example, articles such as above described, are made by processing one of the surfaces of the article so as to dispose the effective grain direction of the material at and adjacent that surface angularly with respect to the material spaced therefrom, and more particularly is this done in the case of materials which are shaped while in a plastic condition as these materials have their lines of weakness extending in the direction of flow of the material while in the plastic state. With specific reference to resinous materials which are commonly shaped into integral articles by being flowed within a shaped mold, the processing of one surface to angularly dispose the effective grain direction of the material at and adjacent that surface is accomplished by moving one mold part relatively to the other while the material of the article is in a plastic condition within the mold. The relative movement'of the rnold parts may be effected while the plastic material is flowing within the mold or after the flow thereof has ceased but while the material still is plastic, although at present the former method is considered preferable.l In the case of articles having at least one surface of revolution, the relative movement of the mold parts may be readily accomplished by merely rotating the part adapted to form the surface of revolution.

For the purpose of more fully describing the method of making articles incorporating the principles of the invention, there is shown in Figs. 7-12 a molding machine including a mold adapted to make the cup-shaped article of Fig. v1. The machine illustrated is primarily adapted and intended for the forming of shaped articles of resinous materials of the type known as thermoplastics, that is, resinous materials which may be repeatedly plasticized by reheatlng. It should, however, be understood that the basic .principles of the method are equally applicable to making articles embodying the invention from other materials exhibiting grain characteristics, including resinous materials of the thermo-setting type, that is, resinous materials which become permanently set and cannot be replasticized once they have been heated to the critical temperature and held there for the curing period of the material.

An injection molding machine of well-known design is shown in Fig. 7. The machine comprises a hopper 1, a material heating chamber 8, a hydraulic piston and cylinder 9 for propelling the molding material through the heating charnber and injecting lit into the mold, a semi-stationary platen Ifor supporting a section of the mold, a movable platen II for supporting another section of the mold, and a second hydraulic piston and cylinder I2 for reciprocating the movable platen.

Reference is now made yto Figs. 8-12 which illustrate in detail the special mold construction embodied in the machine of Fig. 7, and more particularly is reference made to Fig. 8 which is an enlarged cross-sectioned view of the mold in open position. The mold comprises the several sections I3, Ill, I5 and i6. Section I3 is adapted to be fixedly secured to the semi-stationary platen I0 and has a main injection gate Il extending therethrough. One end of this gate is adapted to be engaged by the injection nozzle El of the heating chamber 8 and the other end communicates by means of secondary gates I8 formed in the face of the mold section with tertiary gates I9 which are also formed in the face of the mold section (see Fig. l1).

The mold section Ill has a plurality of impression cavities 20 formed therein. The cavities are properly shaped to form the exterior of the article to be molded and are preferably formed in inserts 2I mounted within the mold section. A gate 22 extends between each of the cavities and the face of the mold section and serves, when the mold lis in closed position, to connect each cavity with one of the gates I9. The mold section is suitably supported for movement to and from engagement with the section I3, this preferably being accomplished by providing dowels 23 carried by the section I3 and upon which section Ill is slidable. It will be understood that the dowels also serve to properly position the two sections sothat when the mold is closed the gates 2.2 are aligned with the gates I9.

For reasons to become hereinafter apparent,

means are preferably provided for cutting the sprue at the polnts where the cavity gates 22 connect with the gates I9. The now preferred construction is illustrated and comprises a cutter plate 24 mounted on the face of mold section Ill by means of cap screws 25. The plate is movable from its noncutting or up position of Fig. 9 to its cutting or down position of Fig. 8 by reason ofthe slots 26 through which screws 25 pass. The cutter plate has knife edges 2l formed thereon at the points where it cuts the sprue (Figs. 8 and 11) and is of a shape to surround the gating system. When the mold is closed the cutter plate is in raised position and is received in a suitably contoured recess 28 in mold section I3 (Fig. 9). Movement of the cutter plate may be effected as desired, as for example, by cam followers 29 sliding in cam grooves 30 in plates 3I attached to mold section I3. The grooves are shaped so as to time the movement of the cutter plate with the opening and closing of the mold.

, In operation it is necessary to allow sufficient separative movement of mold sections I3 and Ill to allow the main gate sprue to be withdrawn from the main gate I'I, but further separation is not desirable as it would obviously increase the bending moment on the dowels 23. Dowels 32 set in section I3 and extending in section Ill function, by-means of 'the enlarged heads 33 and 34 thereon, to limit the separative movement to the optimum amount.

Mold section I6 is bolted or otherwise suitably secured to the movable platen II of the injection machine in proper alignment with the sections I3 and I4. The section carries a plurality of mold parts 35 receivable, when the mold is closed, within the cavities 2n to form the interim surface of the article being molded. y Aspreviously pointed out, the integral lamination of the material of articles incorporating the invention is accomplished by moving one mold part angularly with lrespect to and during the y flow of the material when plastic. In theI moldconstruction illustrated provision is made for so the-heating chamber to expel a shot' of plastic material therefrom. As the piston begins to move it actuates a switch (not shown) control- Vling the .circuit of. motor 48 which as itrotates causes rotation of ring gear 43 and, consequently, rotation of the mold parts 35.

-The material expelled from the heating chamberilows through gates I'l, I8, I9 and 22 into moving the `mold parts 35, each being rotatably lably journaled in the mold section. The shaft is adapted to be rotated through proper gearing. including a speed reduction box 41, by a motor 43 suitably lmounted on the movable platen.

The mold section I` functions as a stripper plate and is provided with a plurality of apertures through which the mold parts extend.

The apertures are preferablyl formed in inserts 49 oi' bearing material in which lthe parts 35 are journaled. The stripper plate is supported between the mold sectionsl I4 and I6 by means of dowels 50 as is apparent in Fig. 8.' Dowels 50 are of the separative movement limiting type and restrict, by means of their headed ends, separative movement of the mold-section I4 and the stripper plate to the amount necessary to allow removal of the articles being molded from between section- I4 and the stripper plate. Mold sections I3 the cavities 20. When thematerial strikes the bottom of mold parts 35 it tends to flow radially outward to form thebottoms of the cupsand then longitudinally of the cavities to form the sides of the cups. Most vof thematerial, and more particularly that adjacent the outer surface of the cups being formed, does flow in the lines just described. However, the material atand adjacent the inner surfaces' of the -cups is caused to L flow spirally in the cup` bottoms and helically in the cup side Walls due to the combination of the force `of injection and the rotating frictional force of the rotating mold parts 35. It will4 be understood that the optimum speed of rotation of the inold parts 35 in relation to the linear speed of ilow of the molding material within the moldcavities will be dependent upon several variables including the kind of molding-material, its degree of plasticity, theshape and wall thickness of the article being molded, and the degree of A angularity desired between the eiective grain diand/I are appropriately recessed at 5I and 52 to accommodate theends -of dowels 5I) when the meld is closed.

Dowel pins 53 are xedly mounted in section l I6 and project toward section I4 through suitable apertures in the stripper plate. The function ofthe dowels is to effect the proper sequen- .tial separation of the mold sections and to this end are provided with grooves 54 in which spring detents 55 in section I4 engage whenfthe mold is closed.

The moldincludes a knock-out pin 56 of usual construction and' operation. The pin is carried by section I6 and projects, when the moldis closed, through the stripper plate and into section I4 and it is axially aligned with main gate I1. The pin is biased to retracted position by a spring 51. It will be understood that the pin is movable to projected position at the proper time during the cycle of operation by the usual means (not shown) usually provided therefor in injection machines.

By way of example, one specific method of forming an article of a material exhibiting grain characteristics and incorporating the principles of the invention will now be described with reference to the apparatus above detailed.

v Assuming. that the molding machine is ready to be put in operation, that is, hopper 'I is illled with a molding material such as polystyrene and heating chamber 8 is charged with molding material in the proper plastic condition, the molding operation :ls initiated. First movable platen II lmoves toward the semi-stationary platen I0 to close the mold and kpush it, together -with the semi-stationary platen, ',to the right (as viewed in Fig. 7) into a position in which injection nozzle 3 is seated against the entrance to main gate I1. The piston in cylinder 9 then advances into retions of the materialat and adjacent one sur-l face and that at and adjacent the other surface.

When the piston has reached the end of its injection stroke it again operates the switch controlling the motor circuit to open the'circuit and stop rotation ofthe mold parts 35. After the necessary interval to allow preliminary setting of the injected material, the piston returns to its original position thus releasing the pressure on the article being molded. Following another interval to allow the injected material to further set, movable platen I0 is 'retracted to open the mold. During the first stage of the retracting movement the semi-stationary platen I0 and the entire mold, stil1 in closed position, move leftof the cam followers 29 in the grooves l3i'I.` By

the time the sections I3 and I4 .have separated to the Aiull extent allowed bythe limiting dowels 32, the cutter plate has severed the sprue consisting ofthe molding material in the gates Il, Itand lI9 which, of courseI was withdrawn from the gates in the usual manner as the mold sections separated. At any desired ,point during the further opening of the mold the knockout pin 56 is actuated in a known manner to 'separate the sprue from the section I'4.

When the sections I3 and I4 have separated to the full extent allowed, further opening movement separates sections I4'and I5 but the sections I5 and I6 remain together, being so held by the molded cups which have become frozen, due to shrinkage, on the mold parts 35. When the sections I4 and I5 have separated to the extend allowed by' the limiting dowels 50, further movement of the stripper plate is impossible and illustrated the sequential operation is automatically controlled in a known manner.

The above described method of forming tubes is satisfactory for relatively short lengths. However, the principles of the invention are equally applicable to the formation of long tubes. Long tubes are now formed, but Without providing for relative angularity of the effective grain direction of different portions of their thickness, by extrusion in a well-known manner. By providing for rotation of one of the forming members, preferably the ring die, long lengths of tube may be made in which the effective grain direction of the material at and adjacent one surface is angularly disposed with respect to the effective grain direction of the material spaced from said surface.

In the foregoing and 'the appended claims, the term surface of revolution is used in its broad mathematical sense to define the shape of a surg article having two opposed surfaces from a plasface conceived as formed by the rotation or revolution of a plane line or curve about a line in itsplane as an axis. Similarly, the term surface of a complete revolution, as used in some of the claims, means that the cross section of the article taken in a plane normal to the central axis thereof comprises a generally endless figure extending around said axis for a full 360.

As used hereinabove and in the appended claims, the terms ow and iio'ws are used to denote the movement of the plasticizable molding material while in the mold cavity from the entrance end to the other.` Said terms are used in the customary sensegem'erally recognized in the plastic molding art. In the preferred embodiment of the invention, but without limitation thereto, said flow of the plastic material is induced by pressure developed in the molding ma; chine.

` While .a detailed description has been given 0f one method embodying the principles of the ticizable homogeneous resinous material having grain characteristics which comprises causing the material to flow within a mold to produce a predetermined effective grain direction in the maerial at and adjacent one of the opposed surfaces due to the flowing of the material, and

f moving the mold part adapted t0 form the other opposed surface in a manner to dispose the eflectivegrain direction of the material at and adjacent said second mentioned surface angularly with respect to said predetermined effective grain direction.

5. The method of making a molded integral article having two opposed surfaces, one of which is a surface of a complete revolution, from a plasticizable homogeneousresinous material having grain characterist'cs which comprises molding the article by causing the material to ilow while plastic within a plural part mold in a direction parallel to the axis of revolution to pro duce grain characteristics at and adjacent one surface of said article due to the flowing of the material and also while the material is plastic rotating one of the mold parts which forms said surface of revolution of the article to dispose the effective grain direction of the material at and adjacent said surface angularly with respect to the effectiveI gia'n direction of the material at and adjacent the other surface of the molded article.

G. The method of making a molded integral article having two opposed surfaces from a plasinvention, many other embodiments within the scope of the invention will be` apparent to those skilled in the art.

What I claim is:

1. An integral molded article having two opposed surfaces one, of which is a surface of a complete revolution, said article being formed of a homogeneous resinous material exhibiting grain characteristics and having the effective grain direction of the material at and adjacent one of the opposed surfaces thereof disposed angularly with respect to the effective grain direction of Cil the material at and Yadjacent the other opposed 2. An integral molded cup-shaped article having two opposed surfaces andformed of a homogeneous resinous material exhibiting grain characteristics, the effective grain direction of the material at and adjacent one of the opposed surfaces being disposed a'ngularly with respect to the effective grain direction of the material at and adjacent the other opposed surface.

3. An integral molded tubular article having inner and outer opposed surfaces and formed of ticizable homogeneous resinous material having grain characteristics, said method comprising causing the material to flow While plast c within a mold to produce a predetermined effective grain direction in the material at and adjacent onf of the opposed surfaces, and while the material is plastic moving the mold part adapted to form the other opposed surface in a manner to dispose the effective grain direction of the material at and adjacent said second mentioned surface angularly with respect to said predetermined effective grain direction.

7. The method of making a molded integral article having two opposed surfaces from a plasticizable resinous material havng grain characteristics, said method comprising molding [the article by causing the material to flow while plasvtic within a mold in a direction to produce a predetermined effective grain direction in the material at and adjacent both of the opposed surfaces, and also while the material is plastic rotating the mold part which forms one surface of said article to change the effective grain direction of the article at and adjacent said surface to dispose said direction angularly to the eifectivegrain direction of the material at and adjacent the other opposed surface.

8. The method of making a molded integral hollow article having two vopposed surfaces, one of which is a surface of a complete revolution, from a plasticizable resinous material having grain characteristics, said method comprising molding the article bycausing the material to flow whle plastic within a mold in a direction to form said hollow article and produce a predetermined effective grain direction in the material at and adjacent both of the opposed surfaces, and also while the material is plastic rotating the mold part which forms one surface of said article to change the effective grain direction vof the article at and adjacent said surface to dispose said direction angularly to the elective grain 'l direction o1 the material at and adjacent thel other opposed surface.

9. The method of making a, molded integral cup-shaped artcle having two opposed surfaces from a plasticizable resinous material having grain characteristics, 'said method comprising molding the article by causing the material to posed surface.

.part which forms one surface of said article to change the effective grain direction of the article at and adjacent said surface to dispose said dil rectlion angularly to the effective grain direction of the material at and adjacent the other op BENJAii/Lna` F. CONNER. 

